Fastener Alignment Guide, Connector and Method

ABSTRACT

The present invention provides a fastener alignment guide comprising a generally planar body and an angled element arranged at an acute angle θ to the body, a first aperture arranged through the angled element and a second aperture arranged through the body, wherein the first aperture and the second apertures are aligned such that a fastener may be inserted progressively through the first and second apertures in use. The present invention also provides a slip-resisting fastener alignment guide comprising a body at least partially arranged in a first plane, the body comprising a first aperture for receiving, in use, at least a portion of a shank of a fastener; and a guidewall extending out of the first plane for guiding the fastener, in use, into the first aperture at an acute angle α to the first plane, wherein the guidewall comprises a first bearing edge or surface upon which an underside of a head of the fastener can bear in use, the body further comprises a second bearing edge or surface upon which the underside of the head of the fastener can bear in use, and the first bearing edge or surface and the second bearing edge or surface are each configured/arranged to resist movement, in use, of the fastener alignment guide relative to the fastener in a first direction parallel to the first plane. 
     The present invention also provides a method of forming the fastener alignment guide and slip-resisting fastener alignment guide.

This patent is a continuation of, and claims the benefit and priorityof, co-pending U.S. patent application Ser. No. 16/081,949, filed Sep.3, 2018, which issued as U.S. Pat. No. 11,608,628, which is herebyincorporated by reference, and U.S. patent application Ser. No.16/081,949 is a 371 application of, and claims the benefit and priorityof, international application PCT/GB2017/050558, filed Mar. 2, 2017,which has expired, which is hereby incorporated by reference, andInternational application PCT/GB2017/050558 claims foreign priority fromGB application 2548090, filed Mar. 3, 2016, which is hereby incorporatedby reference.

The present invention relates to a fastener alignment guide, a connectorcomprising the fastener alignment guide, and a method for fabrication ofa fastener alignment guide.

Fasteners such as nails and screws are commonly used to form connectionsbetween members making up structures, for example the structural membersof load bearing frames. The strength of any connection formed using oneor more fasteners (for example, a screw or a nail) depends in part onthe orientation of the fastener(s) relative to the force exerted on theconnection. The strength of a connection may be critical to the safetyand function of the structure of which the connection is a part. Inconstruction of metal or timber framed buildings, for example, thedirection and orientation of fasteners must always be consistent withthe technical specifications of the frame to ensure that the connectionsbetween the structural members of the frame achieve the requiredresistance to expected loads.

Fasteners may be inserted directly into the members, or may pass througha suitably sized aperture in a connector forming a part of theconnection. Fasteners are often installed perpendicular to the face ofthe members. However, in order to improve the strength of the connectionin response to a particular type of load, for example shear loading, itmay be preferable to insert the fasteners at non-perpendicular angles tothe surface.

When fasteners are required to be installed at predefined angles to thesurface, an installation aid is necessary in order to achieve therequired angle. A template may be provided for checking the angle of afastener as it is installed. However, if the template indicates that theangle is non-optimal, changing the angle of a fastener is difficult onceinstallation has begun and may result in damage to the member in whichthe fastener is being installed.

Various installation tools are available which are costly and must betransported from place to place by the installer. For example, it isknown to use a “pocket screw jig” in the form of a solid blockcomprising one or more angled tunnel-like apertures.

Other secondary machined parts that can be used to align the fastenersat the required angle are also available. However, these can also becostly and take additional time to install.

US20090139153 describes a construction device for spacing and alignmentof structural members or other objects to be affixed. The devicecomprises a fastener guide.

There is a need to provide a fastener alignment guide with lowproduction and raw material costs that is suitable for high volumeproduction.

U.S. Pat. No. 4,291,996 describes a nail-angling device formed bybending a tab of material out of the plane of a connector. U.S. Pat. No.5,603,580 describes a fastener-angling device formed by cutting a slitin a sheet metal connector and pressing the material adjacent to theslit such that it forms a half cone shape.

There is a need to provide a fastener alignment guide which ensuresaccurate alignment of the fastener and is quick and simple to install.There is also a need to provide a fastener alignment guide which hasimproved distribution of loads and resistance to differentialdisplacement (slippage) between the connector and the structural member.

According to a first embodiment, the present invention provides afastener alignment guide comprising;

a generally planar body; and

an angled element arranged at an acute angle θ to the body;

a first aperture arranged through the angled element; and

a second aperture arranged through the body;

wherein the first aperture and the second apertures are aligned suchthat a fastener may be inserted progressively through the first andsecond apertures in use.

Also provided is a method of forming a fastener alignment guidecomprising the steps of:

-   -   forming a first aperture in a first portion of a piece of sheet        metal;    -   forming a second aperture in the piece of sheet metal; and    -   bending the first portion out of the plane of the piece of sheet        metal such that the first portion is arranged at an acute angle        θ to the body, and the first aperture and the second apertures        are aligned such that a fastener may be inserted progressively        through the first and second apertures, in use.

To construct a connection using the fastener alignment guide of thefirst embodiment of the present invention the fastener is simplyinserted through the aligned apertures, which ensure the proper angularalignment of the fastener. The fastener alignment guide may beintegrally formed with a connector, such that no additional componentsor tools are required to install the fastener in the correct alignmentrelative to the connector. The fastener alignment guide of the firstembodiment may also provide more even distribution of loads applied tothe fastener in use.

According to a second embodiment, the present invention provides aslip-resisting fastener alignment guide comprising;

a body at least partially arranged in a first plane, the body comprisinga first aperture for receiving, in use, at least a portion of a shank ofa fastener; and

a guidewall extending out of the first plane for guiding the fastener,in use, into the first aperture at an acute angle α to the first plane;wherein

the guidewall comprises a first bearing edge or surface upon which anunderside of a head of the fastener can bear in use;

the body further comprises a second bearing edge or surface upon whichthe underside of the head of the fastener can bear in use; and

the first bearing edge or surface and the second bearing edge or surfaceare each configured/arranged to resist movement, in use, of the fasteneralignment guide relative to the fastener in a first direction parallelto the first plane.

Also provided is a method of forming a slip-resisting fastener alignmentguide comprising the steps of:

-   -   forming a piece of sheet metal comprising a guidewall arranged        at an acute angle α to a first plane, wherein;        -   the first plane is defined by a body of the piece of sheet            metal; and        -   the guidewall comprises a first bearing edge or surface upon            which an underside of a head of a fastener can bear in use;            and    -   forming a second bearing edge or surface upon which the        underside of the head of the fastener can bear in use;    -   wherein the first bearing edge or surface and the second bearing        edge or surface are each configured/arranged to resist movement,        in use, of the fastener alignment guide relative to the fastener        a first direction parallel to the first plane.

The fastener alignment guide according to the second embodiment of thepresent invention may be used in a connector aligned such that the atleast a portion of applied load in the connection is exerted in thefirst direction. The fastener alignment guide according to the secondembodiment of the present invention reduces the possibility ofdifferential displacement of the connector in such a connection. Theprovision of a second bearing edge or surface configured/arranged toresist movement of the fastener alignment guide relative to the fastenerin a direction parallel to the body, rather than a single point ofcontact between the fastener head and the upper face of the body,results in a more even distribution of applied loads within theconnection, avoiding eccentric loads along the axis of the fastener andreducing the possibility of stress concentrations within the fastenerleading to differential displacement.

The present invention therefore seeks to provide a fastener alignmentguide which has low production and raw material costs and is suitablefor high volume production, provides even load distribution and reducesdifferential displacement of connectors.

The present disclosure also provides a connector comprising a fasteneralignment guide according to any embodiment of the present invention.

Preferred embodiments of the present invention will now be described byway of example only with reference to the accompanying drawings, inwhich:

FIG. 1 is a schematic perspective view of a fastener alignment guideaccording to a first embodiment of the present invention;

FIG. 2 a is a schematic cross section view of the fastener alignmentguide of FIG. 1 ;

FIG. 2 b is a schematic cross section view of the fastener alignmentguide of FIG. 2 a in use;

FIG. 3 is a schematic top elevation view of a sheet metal blank for theformation of the fastener alignment guide of FIGS. 2 a and 2 b;

FIG. 4 is schematic perspective view of a connector comprising afastener alignment guide according to a first embodiment of the presentinvention in use;

FIG. 5 is a schematic cross section view of the connector of FIG. 4 inuse;

FIG. 6 a is a schematic perspective view of a further connectorcomprising a plurality of fastener alignment guides according to a firstembodiment of the present invention in use;

FIG. 6 b is further schematic perspective view of the connector of FIG.6 a;

FIG. 7 a is schematic perspective view of a yet further connectorcomprising a plurality of fastener alignment guides according to a firstembodiment of the present invention in use; and

FIG. 7 b is a further schematic perspective view of the connector ofFIG. 7 a;

FIG. 8 a is schematic perspective view of a yet further connectorcomprising a plurality of fastener alignment guides according to a firstembodiment of the present invention in use; and

FIG. 8 b is a further schematic perspective view of the connector ofFIG. 8 a;

FIG. 9 is a schematic cross section view of a fastener alignment guideaccording to a second embodiment of the present invention;

FIG. 10 is a schematic top elevation view of a sheet metal blank for theformation of the fastener alignment guide of FIG. 9 ; and

FIG. 11 a is a schematic perspective view of the fastener alignmentguide of FIG. 9 ;

FIG. 11 b is a further schematic perspective view of the fasteneralignment guide of FIG. 11 a in use;

FIG. 12 is a schematic cross section view of a further fasteneralignment guide according to a second embodiment of the presentinvention.

Referring first to FIGS. 1 to 3 , there is illustrated a fasteneralignment guide 10 according to a first aspect of a first embodiment ofthe present invention. The fastener alignment guide 10 comprises a body1 formed from sheet metal and an angled element 4 bent out of the body.The angled element 4 comprises a first aperture 2, which is athrough-hole for receiving a portion of the shank of a fastener 6 inuse.

The angled element 4 and the first aperture 2 are arranged in a firstplane 15. The first plane 15 is at an acute angle θ to the body 1, whichis substantially planar and is arranged in a second plane 16.

The first aperture 2 has a diameter ø and is therefore configured toreceive in use a fastener 6 having a shank of diameter ˜ø, where ˜ø ismarginally smaller than diameter ø of the first aperture 2, such thatthe fastener 6 is received in the first aperture 2 but is not a push- orinterference-fit in the aperture.

A fastener alignment axis 11 is defined by the first aperture 2. Thefastener alignment axis 11 is the axis on which the central axis of afastener having a shank of diameter ˜ø will be aligned when received inthe first aperture 2, i.e. the fastener alignment axis 11 is a centralaxis of the first aperture 2. It passes through the centre of the firstaperture 2, parallel to the walls of the first aperture 2 and isperpendicular to the first plane 15. The fastener alignment axis 11 isarranged at acute angle α to the body 1 and is perpendicular to theangled element 4.

The body 1 comprises a second aperture 3. The second aperture 3 is athrough-hole for receiving a portion of the shank of the fastener 6 inuse and is configured to reduce the possibility of misalignment of thefastener 6 on installation. The first aperture 2 and the second aperture3 are aligned such that the shank of fastener 6 can be progressivelyinserted through the first aperture 2 and then the second aperture 3such that when installed it is received within both the first and secondapertures 2, 3 simultaneously.

The fastener alignment axis 11 of the first aperture 2 passes through acentre point of second aperture 3. The centre point is the midpoint ofthe second aperture along its length, width and depth. The secondaperture 3 has a width substantially equal to ø. The second aperture 3is in the form of an elongate slot with a middle portion having aconstant width ø, and semi-circular ends. The middle portion has alength L and each end portion has a length of ø/2. The body 1 has athickness t and the second aperture 3 has a total length l substantiallyequal to:

t/tan α+ø/sin α

Therefore, because the fastener 6 is aligned at angle of α to the secondplane and has diameter ˜ø, the fastener 6 cannot pass through both thefirst aperture 2 and the second aperture 3 unless its central axis issubstantially coincident with the fastener alignment axis 11. Theskilled person will understand that the formula for the length of theaperture may be restated to define the total length l with respect toangle θ.

As shown in FIG. 2 b , the second aperture 3 comprises a proximal end 17a (proximal to the first aperture 2) and a distal end 17 b (distal tothe second aperture 2). In use, when a fastener 6 having a shank ofdiameter ˜ø is inserted into the fastener alignment guide 10 it passesthrough the first aperture 2, which is configured to initially align theshank of the fastener with the fastener alignment axis 11. The shank ofthe fastener 6 may then contact the proximal end 17 a at its upper edge,thereby guiding the shank through the second aperture 3 in line with thefastener alignment axis 11 such that the shank of the fastener alsocontacts or approaches a lower edge of the distal end 17 b. The lateralalignment of the fastener is ensured by the width of the second aperture3, which is equal to the width of the first aperture 2.

Preferably, the fastener alignment guide 10 may be formed as an integralpart of a sheet metal connector 8, for example a joist hanger, bracket,portal frame connector or other connector for use in the construction ofa frame for a building. As shown in FIGS. 4 to 8 , one or moreconnectors 8, 18, 28, 38 comprising one or more fastener alignmentguides 10 may be used to form connections between members 7 instructures, or to fasten a connector 8 to a single member.

The fastener alignment guide(s) 10 may be configured to align thefasteners in the optimal directions for resisting the applied loads inany particular application, for example lateral loading in the header ofa portal frame, as shown in FIGS. 6 a and 6 b , or the vertical loads ina joist hanger, as shown in FIGS. 7 a and 7 b.

To form the fastener alignment guide 10, the first aperture 2 ofdiameter ø is formed in a first portion of a piece of sheet metal. Asecond aperture 3 in the form of an elongate slot is also formed in thebody 1 of the piece of sheet metal. A generally u-shaped channel 5 isformed in the sheet metal around the first portion, as shown in FIG. 3 .The first portion is then bent out of the plane of the body of the pieceof sheet metal (the second plane) until the first portion is arranged atan acute angle θ to the body 1, leaving an opening 5 a in the sheetmetal. The first portion thereby forms the angled element 4. The firstaperture 2 and the second aperture 3 are aligned such that a fastener 6may be inserted progressively through the first and second apertures 2,3 in use, as shown in FIG. 2 b . The first and second apertures aresized and arranged as described above.

Whilst preferred aspects of the first embodiment of the presentinvention have been described above and illustrated in the drawings,these are by way of example only and are non-limiting. It will beappreciated by those skilled in the art that many alternatives arepossible within the ambit of the invention. In the following, likefeatures have been referenced with like reference numerals. In eachcase, only the differences between the further aspect of the firstembodiment and the illustrated aspect described above are described. Forthe avoidance of doubt, any of the features of any one of the followingalternative aspects of the first embodiment may be combined with any oneor more features of any one or more other of the preferred oralternative aspects to form a further alternative aspect of the presentinvention.

In the illustrated aspects of the first embodiment, the angled element 4is integral with the body 1 and is formed by bending a portion of thebody. In alternative aspects, the angled element may be welded orotherwise attached to the body.

In the illustrated aspects of the first embodiment, the first aperture 1is a through hole whose sides are perpendicular to the angled element 4.The angled element 4 is therefore arranged in the first plane 15. Inalternative aspects, the first aperture 1 may be a through hole whosesides and/or central axis 11 are non-perpendicular to the angled element4. In these aspects, the first aperture 2 is arranged in the first plane15 and is configured such that the fastener alignment axis is at angle αto the body 1 and the angled element 4 may be arranged out of the firstplane 15. In any aspect, the angled element 4 may be non-planar, forexample it may be curved.

In any aspect of the first embodiment, the walls of first aperture 2need not be parallel to the fastener alignment axis 11. For example, ifthe fastener 6 has a head comprising an angled underside, the walls ofthe first aperture may be arranged at a complementary angle such thatthe shank of the fastener received in the apertures in use is alignedwith the fastener alignment axis 11.

As illustrated in FIGS. 1 to 3 , the channel 5 is formed such that theangled element 4 has a generally rectangular outline. In alternativeembodiments, the angled element 4 may be formed with a rounded outlineas shown in FIG. 4 . Any other suitable shape of the angled element 4may be adopted, for example the angled element 4 may be generallytriangular. In yet further embodiments, the angled element 4 may beformed from by folding up a tab of material protruding from an edge ofthe body 1, rather than by forming a channel 5 in the body.

In the illustrated embodiments, the first aperture 2 is in the form of acircle or an octagon. In further alternative embodiments, the firstaperture 2 may take any other form, for example a hexagon or a square.The skilled person will understand that the term “diameter” used inrespect of the first aperture is to be understood to refer to equivalentdimensions for alternative shapes, e.g. width if square.

In the illustrated embodiments, the second aperture 3 is in the form ofan elongate slot with a middle portion having a constant width andsemi-circular ends. In alternative embodiments, this slot may take otherforms. For example, the slot may be generally rectangular, orrectangular with rounded corners. In yet further embodiments, the secondaperture 3 may have a width wider than ø or a non-uniform width.

The skilled person will understand that relative dimensions of theapertures and other measurements are subject to the usual manufacturingtolerances. The skilled person will further understand that inapplications where less accurate alignment of the fastener is required,the second aperture 3 may be in the form of an elongate slot, or otheraperture, with dimensions other than those of the illustrated aspects,such that the second aperture 3 acts as a guide element for the fastenerbut accommodates for a broader range of fastener alignments. Forexample, the second aperture 3 may be longer than the described length,such that only one point of contact may be made with the shank of thefastener 6 during insertion.

Referring to FIGS. 9 to 11 , there is illustrated a slip-resistingfastener alignment guide 100 according to a first aspect of a secondembodiment of the present invention. The fastener alignment guide 100comprises a body 101 arranged in a first plane 115. The body 101 isgenerally planar and is formed from sheet metal. The body comprises afirst aperture 102 which is a through-hole for receiving, in use, atleast a portion of a shank of a fastener 106 (shown in dotted lines inFIG. 9 ). The fastener 106 comprises a head having a generally planarunderside 119 and a shank having a central axis, the central axis beinggenerally perpendicular to the generally planar underside 119.

The fastener alignment guide 100 further comprises a guidewall 104. Theguidewall 104 is integral to the body 101 and is formed by bending aportion of the body 101 out of the first plane 115 at an acute angle α,thereby forming the first aperture 102. The first aperture 102 has awidth ø and is therefore configured to receive in use a fastener 106having a shank of diameter ˜ø, where ˜ø is marginally smaller thandiameter of the first aperture 102, such that the fastener 106 isreceived in the aperture 102 but is not a push- or interference-fit inthe aperture 102.

A fastener alignment axis 111 may be defined through the first aperture102. The fastener alignment axis 111 is the axis on which the centralaxis of a fastener having a shank of diameter ˜ø will be aligned whenreceived in the first aperture 102, the shank of the fastener 106bearing against the underside of the guidewall 104. The fasteneralignment axis 111 is parallel to the guidewall 104 and is arranged atan acute angle α to the first plane. The opening of the first aperture102 at the upper face of the body 101 has a length L of approximatelyø/sin α. A second plane 116 may be defined as being perpendicular to thefirst plane 115, the fastener alignment axis 111 being arranged in thesecond plane 116 and at an acute angle to the first plane 115.

The guidewall 104 comprises a bearing surface 114 upon which theunderside 119 of the head of the fastener 106 can bear in use. Thebearing surface 114 is at the distal end of the guidewall 104 from thebody 101. It is generally planar and is perpendicular to the fasteneralignment axis 111. The body 101 further comprises a stop in the form ofa second aperture 103 comprising a linear bearing edge 113 upon whichthe underside 119 of the head of the fastener 106 can bear in use. Inuse, a distal portion of the fastener head is received in the secondaperture 103 such that the underside 119 of the fastener head may bearupon the bearing edge 113.

The bearing surface 114 and the bearing edge 113 are both arranged on athird plane which is perpendicular to the fastener alignment axis 111.They are perpendicular to the second plane 116 and therefore are eachconfigured/arranged to block movement, in use, of the fastener alignmentguide relative to the fastener in a first direction 130 which isparallel to the first plane 115 and aligned with the fastener alignmentaxis 111. The guidewall 104 is therefore also aligned with the firstdirection 130. The bearing surface 114 and the bearing edge 113 eachextend an equal distance on either side of the second plane 116 suchthat load is evenly distributed across the width of the fastener head inuse. Further, the bearing surface 114 and the bearing edge 113 transectthe second plane 116 on opposing sides of the fastener alignment axis111 such that loads transmitted in the first direction 130 aredistributed between the bearing surface 114 and the bearing edge 113.

As shown in FIG. 9 , the first aperture 102 comprises a proximal end 117a (proximal to the guidewall 104) and a distal end 117 b (distal to theguidewall 104). In use, when a fastener 106 having a shank of diameter˜ø is inserted into the fastener alignment guide 100 it passes throughthe first aperture 102, guided by the guidewall 104 and contacts theproximal end 117 a, thereby guiding the shank through the first aperture102 in line with the fastener alignment axis 111 such that the shank ofthe fastener also contacts or approaches an upper edge of the distal end17 b. The lateral alignment of the fastener is ensured by the width ofthe first aperture 102, which is marginally wider than the diameter ofthe shank of the fastener.

Whilst preferred aspects of the second embodiment of the presentinvention have been described above and illustrated in the drawings,these are by way of example only and are non-limiting. It will beappreciated by those skilled in the art that many alternatives arepossible within the ambit of the invention. In each case, only thedifferences between the further aspect of the second embodiment and theillustrated aspect described above are described. For the avoidance ofdoubt, any of the features of any one of the following alternativeaspects of the first embodiment may be combined with any one or morefeatures of any one or more other of the preferred or alternativeaspects to form a further alternative aspect of the present invention.

Referring to FIG. 12 , there is illustrated a slip-resisting fasteneralignment guide 100 according to a second aspect of the secondembodiment of the present invention. In the following, like featureshave been referenced with like reference numerals. This aspect comprisesa stop in the form of a protrusion 123 extending upwards from the body101. The protrusion comprises the bearing edge 113, and in use, a distalportion of the fastener head is received behind the protrusion 123(relative to the first aperture 102) such that the underside 119 of thefastener head may bear upon the bearing edge 113.

In the illustrated embodiments, the stop takes the form of a secondaperture 103 or protrusion 123. The skilled person will understand thatthe stop is a barrier feature arranged transverse to the second plane116 against which the underside 119 of the fastener head abuts to block,in use, movement of the fastener alignment guide 100 relative to thefastener in the first direction. In any aspect of the second invention,therefore, the stop may take alternative forms, such as a recess,embossment or ridge formed by folding or bending the body or by additionof a protruding element, for example by welding. Similarly, the skilledperson will further understand that the bearing edge 113 may in anyaspect of the second invention take the form of a second bearing surfaceconfigured that the underside 119 of the fastener head bears against thesecond bearing surface in use, the second bearing surface being arrangedin the third plan. The bearing surface 114 may in any alternativeaspects be a first bearing edge arranged in the third plane.

The guidewall 104 may, in any alternative aspects, be formed by weldingor otherwise attaching a separate element to the body 101.

In any aspect of the second invention, the bearing edges or surfaces maybe discontinuous and/or may be transverse, but not perpendicular to, thesecond plane. Similarly, the bearing edges or surfaces may extend unevendistances on either side of the second plane. Preferably, both of thebearing surfaces or edges are configured to abut the underside 119 ofthe fastener head evenly across its width.

In the illustrated embodiments, the guidewall is substantially planarand is arranged at angle α to the first plane. In alternative aspects ofthe second embodiment, the guidewall may extend at a different angle ortake an alternative shape, for example a curve, provided that the firstbearing surface and the point of connection between the guidewall 104and the rest of the body 101 is arranged on an axis at angle α to thefirst plane, such that it may guide the shank of the fastener 106 intothe first aperture 102 at angle α to the first plane.

In the illustrated embodiments, the guidewall 104 comprises a planarface configured to guide the shank of the fastener into the firstaperture 102 at angle α to the first plane. In alternative aspects ofthe second embodiment, the guidewall 104 may comprise a curved face, anedge, or a discontinuous face or edge configured guide the shank of thefastener 106 into the first aperture 102 at angle α to the first plane.

The skilled person will understand that in alternative aspects thefastener alignment guide may be used with a fastener with a head havinga non-planar underside. If the underside of the head is curved orangled, first and second bearing surfaces/edges may be formed with acomplementary curve or angle, provided that they remain transverse tothe second plane such that they are each configured/arranged to blockmovement, in use, of the fastener alignment guide relative to thefastener in the first direction 130.

The skilled person will understand that relative dimensions of theapertures and other measurements are subject to the usual manufacturingtolerances. The skilled person will further understand that inapplications where less accurate alignment of the fastener is required,the first aperture 102 may have dimensions other than those of theillustrated aspects, allowing for greater variation in the alignmentcentral axis of the shank of the fastener after insertion.

Preferably, one or more fastener alignment guides 100 according to anyaspect of the second embodiment may be formed as an integral part of asheet metal connector 8, 18, 28, 38, for example a joist hanger,bracket, portal frame connector or other connector for use in theconstruction of a frame for a building, such as those shown in FIGS. 4to 8 .

In use, the fastener alignment guide 100 will preferably be aligned suchthat at least a component of the loading expected in a particularapplication will be aligned with the first direction 130.

To form the fastener alignment guide 100, the second aperture 103 isformed in a first portion of a generally planar piece of sheet metal. Agenerally u-shaped slot 105 is formed in a second portion of the pieceof sheet metal to form a tab having a planar end face. The tab is bentout of the plane of the piece of sheet metal to an angle α relative tothe plane of the piece, thereby forming the first aperture 102. Thefirst and second apertures are sized and arranged as described above.

Whilst preferred aspects and embodiments of the present invention havebeen described above and illustrated in the drawings, these are by wayof example only and are non-limiting. It will be appreciated by thoseskilled in the art that many alternatives are possible within the ambitof the invention.

Preferably, the fastener alignment guide is formed as an integral partof a sheet metal connector 8,18,28, 108, meaning that the fasteneralignment guide and the connector from a piece of sheet metal withoutaddition of extra material, for example without welding, gluing etc. Infurther alternative embodiments, the fastener alignment guide may befabricated as a separate component, and subsequently connected to alarger component, for example a connector.

In the present application, relative geometrical and/or positionalterms, for example “top” and “upper” are used with reference to theorientation of the fastener guides 10, 100 as shown in FIGS. 2 and 9 .The skilled person will understand that such terms are purely used forease of reference and do not limit the actual orientation of thefastener alignment guide in use. Further, the skilled person willunderstand that the term “proximal” is used to refer to the nearest partand the term “distal” is to be used to refer to the furthest part.

The fastener alignment guides of the illustrated embodiments are formedfrom a single piece of sheet metal, without the need for subsequentwelding or other additive processes. They are formed by stamping,cutting, folding and/or otherwise deforming the sheet metal. Preferably,the fastener alignment guide of any embodiment may be formed as anintegral part of a sheet metal connector for example a joist hanger,bracket, portal frame connector or other connector for use in theconstruction of a frame for a building. The term “metal” is to beunderstood to include alloys and metal composites. In alternativeaspects, the fastener alignment guide may be formed from othermaterials, for example sheet plastic, composites or resins. Theproduction of connectors and other construction components in sheetmetal may result in lower manufacturing costs, lower raw materials costsand/or increased speed of manufacture than for cast components, makingthe use of sheet metal in such component more conducive to high volumeproduction.

Although the body 1 of all of the illustrated embodiments is generalplanar, the skilled person will understand that the body 1 need not beentirely planar. Depending on the required application, the body may becurved or bent and may include, for example, embossments, flanges,protrusions or other additional features not shown in the illustratedembodiments.

Although the examples described in this specification relate toconstruction of load bearing frames, any of the fastener alignmentfeatures according to the present invention may be applied to any otherconnection requiring installation of a fastener, for example in theconstruction of furniture or low-load bearing applications in buildingconstruction such as fixing panels in place.

In the illustrated embodiments, the fasteners received in the fasteneralignment guide in use are screws and/or nails. The skilled person willunderstand that the fastener alignment guide may equally be used toalign bolts or any other fastener having a substantially linear shaft orshank.

The skilled person will understand that the steps of the methods offabricating the fastener alignment guide may be carried out in anypractical order, and that the method according to the first embodimentof the present invention is not limited to producing a fasteneralignment guide with the specified dimensions, but may be a fasteneralignment guide having the form of any aspect or embodiment of thepresent invention.

Each feature disclosed in this specification (including the accompanyingclaims and drawings), may be replaced by alternative features servingthe same, equivalent or similar purpose, unless expressly statedotherwise. Thus, unless expressly stated otherwise, each featuredisclosed is one example only of a generic series of equivalent orsimilar features. In addition, all of the features disclosed in thisspecification (including the accompanying claims and drawings), and/orall of the steps of any method or process so disclosed, may be combinedin any combination, except combinations where at least some of suchfeatures and/or steps are mutually exclusive.

Accordingly, while many different embodiments of the present inventionhave been described above, any one or more or all of the featuresdescribed, illustrated and/or claimed in the appended claims may be usedin isolation or in various combinations in any embodiment. As such, anyone or more feature may be removed, substituted and/or added to any ofthe feature combinations described, illustrated and/or claimed. For theavoidance of doubt, any one or more of the features of any embodimentmay be combined and/or used separately in a different embodiment withany other feature or features from any of the embodiments. As such, thetrue scope of the invention is that as set out in the appended claims.

We claim:
 1. A fastener alignment guide comprising; a generally planarbody; and an angled element arranged at an acute angle θ to the body; afirst aperture arranged through the angled element; and a secondaperture arranged through the body; wherein the first aperture and thesecond apertures are aligned such that a fastener may be insertedprogressively through the first and second apertures in use.
 2. Afastener alignment guide as claimed in claim 1 wherein the angledelement is generally planar.
 3. A fastener alignment guide as claimed inclaim 1 wherein the angled element is formed by bending or folding aportion of the body.
 4. A fastener guide as claimed in claim 1 whereinthe fastener alignment guide is formed from sheet metal.
 5. A fasteneralignment guide as claimed in claim 1 wherein the first aperture has adiameter ø and is configured to retain a fastener having a diameter ˜øin use such that a central axis of the fastener is arrangedsubstantially perpendicular to the angled element.
 6. A fasteneralignment guide as claimed in claim 1 wherein the second aperturedefines a fastener alignment axis arranged at an acute angle α to thebody, the first aperture has a diameter ø, the body has a thickness tand the second aperture has a total length l substantially equal tot/tan α+ø/sin α.
 7. A fastener alignment guide as claimed in claim 1 inwhich a central axis of the first aperture passes through a centre pointof the second aperture.
 8. A fastener alignment guide as claimed inclaim 1 wherein the first aperture has a diameter ø and the secondaperture has a width substantially equal to ø.
 9. A fastener alignmentguide as claimed in claim 1 wherein the second aperture comprises: afirst end, the first end being proximal to the first aperture; and asecond end, the second end being distal to the first aperture; whereinthe first aperture has a diameter ø and is configured to receive afastener having a shank of diameter ˜ø in use; and the second apertureis configured such that, in use, the shank of the fastener contacts boththe first and second ends.
 10. A fastener alignment guide as claimed inclaim 1 in combination with a fastener having a shank of diameter ˜ø.11. A connector comprising a fastener alignment guide as claimed inclaim
 1. 12. A connector as claimed in claim 11 wherein the connector isformed from sheet metal.
 13. A connector as claimed in claim 11 whereinthe fastener alignment guide is formed as an integral part of theconnector.
 14. A connector as claimed in claim 13 wherein the connectoris a joist hanger, bracket, angle bracket, portal frame connector orother connector for use in construction.
 15. A method of forming afastener alignment guide comprising the steps of: forming a firstaperture in a first portion of a piece of sheet metal; forming a secondaperture in the piece of sheet metal; and bending the first portion outof the plane of the piece of sheet metal such that the first portion isarranged at an acute angle θ to the body, and the first aperture and thesecond apertures are aligned such that a fastener may be insertedprogressively through the first and second apertures, in use.
 16. Aslip-resisting fastener alignment guide comprising; a body at leastpartially arranged in a first plane, the body comprising a firstaperture for receiving, in use, at least a portion of a shank of afastener; and a guidewall extending out of the first plane for guidingthe fastener, in use, into the first aperture at an acute angle α to thefirst plane; wherein the guidewall comprises a first bearing edge orsurface upon which an underside of a head of the fastener can bear inuse; the body further comprises a second bearing edge or surface uponwhich the underside of the head of the fastener can bear in use; thefirst bearing edge or surface and the second bearing edge or surface areeach configured/arranged to resist movement, in use, of the fasteneralignment guide relative to the fastener in a first direction parallelto the first plane; the body further comprises a stopconfigured/arranged to resist or block movement, in use, of the fasteneralignment guide relative to the fastener in the first direction; and thestop comprises a recess, aperture or protrusion for receiving a portionof the head of the fastener in use, the second bearing edge or surfacecomprising at least a portion of an edge or surface of the recess,aperture or protrusion.
 17. A slip-resisting fastener alignment guide asclaimed in claim 16 wherein the first bearing edge or surface and thesecond bearing edge or surface are each arranged substantiallytransverse to the first direction.
 18. A slip-resisting fasteneralignment guide as claimed in claim 16 wherein the guidewall comprises aportion of the body which is bent out of the first plane, therebyforming the first aperture.
 19. A slip-resisting fastener alignmentguide as claimed in claim 16 wherein the guidewall is arranged at anangle of substantially a to the first plane.
 20. A slip-resistingfastener alignment guide as claimed in claim 16 wherein the firstbearing edge or surface comprises an end face or edge of the guidewall.21. A slip-resisting fastener alignment guide as claimed in claim 16wherein; a fastener alignment axis is defined through the firstaperture; a second plane is defined perpendicular to first plane, thefastener alignment axis being arranged in the second plane and at anacute angle α to the first plane and the first bearing edge or surfaceand the second bearing edge or surface are configured such that loadtransfer between the fastener and the fastener alignment guide in use isequally balanced on either side of the second plane.
 22. Aslip-resisting fastener alignment guide as claimed in claim 16 incombination with a fastener.
 23. A slip-resisting fastener alignmentguide as claimed in claim 22 wherein the fastener comprises a headhaving a generally planar underside and a shank having a central axis,the central axis being generally perpendicular to the generally planarunderside of the head.
 24. A slip-resisting fastener alignment guide asclaimed in claim 16 wherein the first bearing edge or surface and/or thesecond bearing edge or surface is linear.
 25. A connector comprising aslip-resisting fastener alignment guide as claimed in claim
 48. 26. Aconnector as claimed in claim 25 wherein the connector is formed fromsheet metal.
 27. A connector as claimed in claim 25 wherein theslip-resisting fastener alignment guide is formed as an integral part ofthe connector.
 28. A connector as claimed in claim 27 wherein theconnector is a joist hanger, bracket, angle bracket or portal frameconnector or other connector for use in construction.
 29. A method offorming a slip-resisting fastener alignment guide comprising the stepsof: forming a piece of sheet metal comprising a guidewall arranged at anacute angle α to a first plane, wherein; the first plane is defined by abody of the piece of sheet metal; and the guidewall comprises a firstbearing edge or surface upon which an underside of a head of a fastenercan bear in use; and forming a second bearing edge or surface upon whichthe underside of the head of the fastener can bear in use, wherein: thefirst bearing edge or surface and the second bearing edge or surface areeach configured/arranged to resist movement, in use, of the fasteneralignment guide relative to the fastener a first direction parallel tothe first plane; the step of forming the second bearing edge or surfacecomprises forming a stop in the body; and the stop is one of a recess,an aperture or a protrusion in or on the body.
 30. A method of forming aslip-resisting fastener alignment guide as in claim 29 wherein theguidewall is formed by bending a portion of the body out of the firstplane.